Channel grid members with t-rail and hanger bracket



NOV. 29, 1966 STAHLHUT 3,287,874

CHANNEL GRID MEMBERS WITH T-RAIL AND HANGER BRACKET Filed Aug. 5, 1963 2Sheets-Sheet 1 "Nov. 29, 1966 1.. G. STAHLHUT 3,237,874

RAIL AND HANGER BRACKET CHANNEL GRID MEMBERS WITH T 2 Sheets-Sheet 2Filed Aug. 5, 1963 FIG.8

FIGS

United States Patent Ofifice Patented Nov. 29, 1966 3,287,374 CHANNELGRID MEMBERS WITH T-RAIL AND HANGER BRACKET Leo G. Stahlhut, Kirkwood,Mo., assiguor to K-S-H Plastics, Inc., Kirkwood, Mo., a corporation ofMissouri Filed Aug. 5, 1963, Ser. No. 299,737 (Ilaims. (Cl. 52-720) Thisinvention relates to suspended ceilings.

It has become common to form the ceiling of buildings by using a grid ofshapes suspended on hangers, such as wires or straps, secured to apermanent overhead supporting structure. Commonly, ceiling tiles arelaid on ledges provided by the grids.

The most common form of grid member has been the so-called T-rail. The Tis inverted, the head serving to provide a shelf, and the stem, a meansof connecting the rail to the wire or strap. The head of the T can alsobe used as a spline, extending into a kerf in the vertical edge of aceiling tile. However, in this latter arrangement, it can be seen thatthe ceiling must be installed serially as a unit, i.e., with the firstrail, then the first row of ceiling tile, then the second rail, and soon. It also precludes accessibility to the space between the suspendedceiling and the supporting structure except in those areas in whichspecial provision is made by not using the Trails as splines.

When ceiling tile is merely laid on the head of the T-rail, the tilestend to breathe. With the advent of extremely lightweight tile, thetiles may actually float from their shelf on the T-rails when a pressuredifferential is created between the room space below the suspendedceiling and the space above it.

Another problem in the use of the grid members known heretofore has beenin the interlocking of cross members. This now must either beaccomplished with the use of clips, or else the interlock is notpositive.

One of the objects of this invention is to provide a suspended ceiling,the grid members of which are unobstrusive in appearance, positive intheir interlock, and which retain ceiling tiles against unwantedmovement, but permit their release when their release is desired.

Another object of this invention is to provide a suspended ceiling withceiling tiles peculiarly adapted to use with the grid members of thisinvention.

Still another object of this invention is to provide a suspended ceilingwith hanger brackets peculiarly adapted to use with the grid members ofthis invention, which provide flexibility of use with relative rigidityin use as compared with hanger brackets known heretofore.

Other objects will become apparent to those skilled in the art in thelight of the following description and accompanying drawing.

In the drawings,

FIGURE 1 is a fragmentary perspective view, partly in section, showingone embodiment of ceiling of this invention;

FIGURE 2 is a sectional view taken along the line 2-2 of FIGURE 1;

FIGURE 3 is a sectional view taken along the line 3-3 of FIGURE 1;

FIGURE 4 is a sectional view taken along the line 4-4 of FIGURE 1;

FIGURE 5 is a fragmentary perspective view, partly in section, showingwhat, in this embodiment, is a cross rail grid member;

FIGURE 6 is a fragmentary view in perspective, partly in section, ofwhat, in this embodiment, is a main rail grid member;

FIGURE 7 is a view in side elevation of a cross rail grid member;

FIGURE 8 is a view in side elevation of a main rail grid member;

FIGURE 9 is a sectional view showing, in end elevation, a hanger bracketof this invention, mounted on a grid member; and

FIGURE 10 is a sectional view taken along the line 1010 of FIGURE 9,showing the hanger bracket of FIGURE 9 in side elevation.

In accordance with this invention, generally stated, a suspended ceilingis provided, made up with grid members which have a pair of transverselyspaced vertical walls connected by and integral with a web. The wallshave outboardly projecting, longitudinally extending tongues, preferablyone on each wall, and preferably integral with the walls. Means areprovided for connecting the members to the hanger. These means, betweenthe vertical walls and below the top edge of the walls, define, with theweb, a pair of channels opening transversely of the web. In thepreferred embodiment, these means take the form of a small T section,the stern of which is integral with the upper surface of the web. Thehead of the T defines, with the web, outwardly transversely openingchannels, and with the adjacent walls, a pair of passages.

A hanger bracket is provided, which has transversely directed feet,located in the channels, and bearing against the underside of thechannel-defining means. The hanger bracket also has a pair of ears,extending transversely closely adjacent the inner surfaces of thevertical walls, which inhibit transverse rocking of the hanger withrespect to the grid member. The feet of the hanger bracket arepreferably staggered longitudinally of the grid member and the hangerbracket is provided with bearing legs which are spaced close to theupper surface of the channel-defining means, so as to inhibit rocking ofthe hanger bracket in a direction longitudinally of the grid member.

Ceiling tiles are provided which are particularly adapted for use withthe grid of this invention. The ceiling tiles of this invention arelight in weight, generally cellular, and of substantial thickness. Theyare formed with a central panel, and a rim. The rim extends upwardlybeyond the plane of the central panel, and, in turn, is provided withoutboa-rdly projecting stop lugs. In the preferred embodiment shown, thestop lugs take the form of an overhanging lip, the lower surface ofwhich defines one edge of a tongue-receiving goove. In one of theembodiments shown, the lip is downwardly outwardly sloped. The distancebetween the upper edge of a lip and the upper edge of the lip on theopposite, parallel side of a rectangular ceiling tile is less than theleast distance between corresponding grid members upon which the ceilingtile is to be mounted. In this embodiment, then, the tile can be mountedfrom below the grid. In another embodiment, the stop lugs overhangvertical walls of the grid members to such an extent that they must beput in from above. In either event, the lip and grids are soproportioned as to ensure the engagement of the lip and the grids, whenthe ceiling tiles are mounted. In the preferred embodiments, the tongueof the vertical walls of the grid members projects into thetongue-receiving groove of the ceiling tile. In every case, the gridmaterial must flex to permit the installation of the ceiling tile, andits resilience ensures a positive mounting of the ceiling tiles in thegrid openings, whereby floating of the ceiling tiles is eliminated.

In the preferred form of ceiling tiles, the rim is tapered inboardlydownwardly, in such a way as to leave a small space between the verticalwalls of the grid members and the lower edge of the rim of the ceilingtile. This arrangement facilitates the installation, along grid members,of wall partition brackets, which can fit between the ceiling tile andthe grid member.

Referring now to the drawing for one illustrative embodiment of ceilingof this invention, reference numeral 1 indicates an assembled ceiling,which includes grid members of two sorts, main rails 2 and cross rails3, and one embodiment of ceiling tiles 4. Two types of ceiling tiles areshown in the drawings, one in FIGURES l and 2 and another (49) in FIGURE9, differing only in the transverse width of stop lugs, as will beexplained in detail hereinafter. In addition, the ceiling of thisinvention includes a hanger bracket 5, shown in FIGURES 9 and 10.

Referring now particularly to FIGURES 2 through 6, it will be seen thatboth of the grid members 2 and 3 have transversely spaced vertical walls12 and 13, connected by and integral with a web 14. In the embodimentshown, the web 14 connects the vertical spaced walls 12 and 13 alongtheir lowermost edges. The channel-defining means between the verticalWalls, in this embodiment, takes the form of a T section 15, with a stem16 integral with the web 14, and a head 17 integral with the stem. Alongthe top edge of the walls 12 and 13, and projecting transverselyoutboardly are tongues 18, each with a downwardly outwardly slopedbeveled face 19.

Referring now particularly to FIGURES 3, 5, and 7 for a description ofthe cross rail 3, normally the cross rail 3 is shorter than the mainrail. For example, for a 2' by 4 module, the main rail may be 12 feetlong, the cross rail 8 feet long. The main rail will then be notched toreceive the cross rails on two foot centers. However, the members can beof different lengths and notched for dilferent modules.

In the embodiment shown in FIGURES 3, 5, and 7, the coss rail isprovided with a notch or opening 31, extending through the connectingweb 14 and the T section 15. The side edges of the opening 31 aredefined by walls 32 spaced apart only slightly farther than the distancebetween the outside surfaces of the walls 12 and 13. The upper boundaryof the notch 31, at each of the walls 12 and 13 is defined by adownwardly projecting apron 33. Each of the walls 12 and 13, of thecross rail 3 is provided with a pair of keeper holes 35, near but belowthe tongue 18.

Referring now particularly to FIGURES 4, 6, and 8,

for an embodiment of main rail, the main rail 2 has a main rail opening21, extending through the tongues 18 downwardly into the walls 12 and13. The sides of the opening 21 are defined by edges 22, spaced, in eachwall, only slightly farther from one another than the distance betweenthe outer surfaces of the walls 12 and 13. Near but below the tongues18, the edges of the opening 21 are defined by pairs of inwardlyprojecting prongs 23. A bottom of the opening 21 in each wall is definedby an upwardly projecting saddle 25.

As is best shown in FIGURES 3 and 4, the main rail 2 and the cross rail3 are assembled at right angles to one another, with the notch-definingwalls 32 of the cross rail embracing the lower part of the walls 12 and13 of the main rail, below the saddle 25, and with the openingdefiningwalls 22 of the main rail embracing the upper part of the walls 12 and13 of the cross rail. The prongs 23 spring into the keeper holes 35 (seeFIGURE 4). The aprons 33 fit snugly between the walls 12 and 13 of themain rail, while the saddles 25 fit snugly between the walls 12 and 13of the cross rail.

This provides a very substantial joint. The rails can move in nodirection with respect to one another, except to the extent permitted bythe tolerances of the walls and openings and,.the give of the materials.

As can be seen from FIGURES 7 and 8, the ends of the grid members areprovided with half an opening. That is to say, the main rails are cutoif through the center line of the two saddles 25; the cross rails arecut oil through the center lines of the aprons 33. In making a ceilinginstallation, the main and cross rail joints are staggered, so that theends of both main and cross rails never coin- 4 cide. It can be seen,that in such a staggered arrangement, the joints provided are stillsubstantial and rigid, since the interlocking of the saddles and aprons,and the engagement of the prongs in the keeper holes provides asubstantial rigidity in every case.

Referring now to FIGURES 9 and 10, the hanger bracket 5 is a plate 51,generally rectangular in outline, with a hanger strap-receiving hole 52near its upper edge. In the center part of its lower edge, the plate 51has a pair of feet '55, inturned toward one another and spread so as tostraddle the head 17 of the T-section 15, and project beneath the head.At the two outer parts of the lower edge of the plate 51, are bearinglegs 56, which fit closely. adjacent the top surface of the head 17 ofthe T-section. Thus, between the feet 55 and the bearing legs 56,rocking in the plane of the plate 51 is largely inhibited. Ears 53,projecting in opposite directions from the plane of the plate 51, arestruck from the plate at such a distance from the bottom as to be withinthe compass of the walls 12 and 13 when the hanger bracket is mounted ona grid member. The cars 53 extend sufiiciently closely adjacent theinner surfaces of the walls 12 and 13 to inhibit rocking of the plate atright angles to the plane of the plate. The hanger bracket 5 is merelyslid onto the T-section from one end of a grid member.

The suspension of the grid members, by means of hanger straps 6, isconventional, except for the greater flexibility provided by the freeadjustability of the hanger brackets 5.

When the grid members have been assembled and suspended, the ceilingpanels 4 may be installed. The type of ceiling tile 4 shown in FIGURE 2.may be installed from the underside of the grid. The ceiling tiles aremade of material of substantial thickness and resilience. Each of themhas a central panel 41, a rim 42 integral with the central panel andextending above the central panel, and stop lugs 43 extending outboardlyfrom and integral with the rim. In the complete ceiling tile, the outermargins of opposite stop lugs are spaced a greater distance than thespace between opposite grid members, so that the stop lugs must beflexed inboardly to install the tile. Reinforcing ribs 46 are providedon the upper surface of the central panel, integrally therewith.

In the ceiling tile 49 shown in FIGURE 9, stop lugs 58 extend so farover the top edge of the grid member on which it is notched as to makeit necessary to insert the tile from the top.

Numerous variations in the construction of various elements of thisinvention, within the scope of the appended claims will occur to thoseskilled in the art in the light of the foregoing disclosure. Merely byway of example, the channel-defining means in the grid members may takethe form of facing shelves integral with an projecting from the sidewalls, and terminating short of meeting to define a central passage. Thehanger bracket feet can then be bent outwardly to fit into the channelsbeneath the shelves. The Web joining the spaced vertical walls of thegrid members may be positioned above the very bottom edges of the walls,to form a decorative effect or to admit partition runners. The stop lugson the ceiling tile can be continuous or intermittent, and ifcommunication between the spaces along and below the ceiling is desired,the edge of the tiles between interrupted stop lugs can be serrated orrecessed. These are merely illustrative.

Having thus described the invention, what is claimed and desired to besecured by Letters Patent is:

1. Grid members for a suspended ceiling comprising a main rail and across rail, both of said rails comprising a pair of transversely spacedvertical walls connected at their lower edges by and integral with aweb, and an outboardly projecting, longitudinally extending tongue onand integral with each of said respective walls, said main rail havingtransversely aligned openings each extending from the upper edge of thevertical wall, each of said openings having its side and lowerboundaries respectively defined by a pair of facing inwardly projectingprongs and a central upwardly projecting saddle; said cross rail havingan opening through the web and lower part of its vertical walls, theupper boundary of the opening in each wall being defined by a downwardlyprojecting apron, said cross rail having a pair of keeper holes adaptedto receive the prongs of a main rail, said main rail and cross railopenings being of a size closely to admit the walls of the other of therails, and the saddle of the main rail and the apron of the cross railbeing of a width to fit closely between the vertical wall of the crossrail and main rail respectively, when the grid is assembled, and theprongs of the main rail extend into the keeper holes of the cross rail.

2. A grid assembly for a suspended ceiling comprising a grid memberhaving a pair of transversely spaced vertical walls connected at theirlower edges by and integral with a web, a T-rail on and the stem ofwhich is integral with the upper surface of the web, said T-rai'l beingbetween and below the top of the vertical walls, and a hanger bracket,mounted on said T-rail, said hanger bracket comprising a plate, ears onsaid plate projecting toward the two walls of said member and closelyadjacent, but slidable with respect thereto, and inturned feet, alongthe lower edge of said plate, said feet slidably engaging the undersideof the head of the T-rail.

3. The sub-assembly of claim 2 wherein the feet are integral with theplate, and staggered longitudinally of the T-rail, and bearing legs areprovided, integral with the plate, closely adjacent the upper surface ofthe head of the T-rail.

4. A grid member for a suspended ceiling comprising a pair oftransversely spaced vertical walls connected at their lower edges by aweb integral with said walls to form a U-shaped, open-topped member, atongue projecting outboardly from the upper edge of each of said wallsand having a beveled outer edge, and a T-rail with its stem integralwith the upper surface of said web and its head between, but below theupper edge of the said vertical walls, said head defining with said weba pair of channels and with said walls a pair of passages.

5. A grid member for a suspended ceiling, comprising a pair oftransversely spaced vertical walls connected at their lower edges by andintegral with a web, an outboardly projecting, longitudinally extendingtongue on and integral with each of said respective walls, and a T-railon and the stem of which is integral with the upper surface of the web,between said vertical walls, below the top edge thereof, the head of theT defining, with the web and stem, a pair of channels opening towardtheir adjacent walls.

References Cited by the Examiner UNITED STATES PATENTS 1,214,928 2/1917Lachman 52668 1,786,822 12/1930 Carr 52668 X 2,362,859 11/1944Rosenblatt 52484 X 2,667,242 1/1954 Kullmer 52732 X 2,904,140 9/ 1959Cleary 52377 2,920,357 1/1960 Ericson 52475 X 2,921,656 1/1960 Goyer52485 X 2,935,152 5/1960 Maccaferri 52485 X 3,174,580 3/1965 Schulz etal 52145 X FOREIGN PATENTS 821,513 10/1959 Great Britain.

FRANK L. ABBOTT, Primary Examiner.

A. C. PERHAM, Assistant Examiner.

2. A GRID ASSEMBLY FOR A SUSPENDED CEILING COMPRISING A GRID MEMBERHAVING A PAIR OF TRANSVERSELY SPACED VERTICAL WALLS CONNECTED AT THEIRLOWER EDGES BY AND INTEGRAL WITH A WEB, A T-RAIL ON AND THE STEM OFWHICH IS INTEGRAL WITH THE UPPER SURFACE OF THE WEB, SAID T-RAIL BEINGBETWEEN AND BELOW THE TOP OF THE VERTICAL WALLS, AND A HANGER BRACKET,MOUNTED ON SAID T-RAIL, SAID HANGER BRACKET COMPRISING A PLATE, EARS ONSAID PLATE PROJECTING TOWARD THE TWO WALLS OF SAID MEMBER AND CLOSELYADJACENT, BUT SLIDABLE WITH RESPECT THERETO, AND INTURNED FEET, ALONGTHE LOWER EDGE OF SAID PLATE, SAID FEET SLIDABLY ENGAGING THE UNDERSIDEOF THE HEAD OF THE T-RAIL.